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CONTENTS

S.No. DESCRIPTION ANNEXURE Page No. 1. SCOPE OF WORK ANNEXURE-1 Page: 2 2. TECHNICAL SPECIFICATIONS FOR 30ton EOT

CRANE ANNEXURE-2

Page: 3 - 17

3. LIST OF MANUFACTURERS / SPECIFIC BRANDS FOR BOUGHT-OUT ITEMS

ANNEXURE-3 Page: 18

4. GENERAL CONDITIONS FOR 30ton EOT CRANE

ANNEXURE-4 Page: 19-30

5. SUPPLY REQUIREMENTS FOR PROVIDING CRANE SUPPLIER’S (OWN MAKE) GEAR BOXES FOR EOT CRANE

ANNEXURE-5 Page: 31

6. IS CODES AND STANDARDS ANNEXURE-6 Page: 32-33 7. CALCULATIONS TO BE SUBMITTED ANNEXURE-7 Page: 34-35 8. TEST CERTIFICATES & INSPECTION

REPORTS TO BE SUBMITTED ANNEXURE-8 Page: 36

9. FORMAT FOR PRICE BID (PART-II) ANNEXURE-9 Page: 37-38 10. (Figure-1) CRANE CLEARANCE DIAGRAM - Page: 39

Note:

1. Vendor should go through all the lines/words given in the following pages (Page 2-38) thoroughly.

2. Vendor should agree all the points given in the following pages (Page 2-36). If Vendor disagrees any point it should be clearly mentioned as “disagreed” and the reason shall be mentioned.

3. Vendor must submit point wise reply to specifications; Deviations if any must be separately submitted with reasons for each.

4. Technical specifications, dimensions of components given by the purchaser should be

followed strictly.

5. Clarification (if any) in the Tender specifications/General conditions shall be Annexed in “separate heading” in the last page of Technical Bid.

6. EXPERIENCE IN THE FIELD : Vendor should be a reputed manufacturer of cranes and should be conversant with the manufacturing of cranes. A documentary proof showing the experience in the field should be enclosed along with Technical Bid.

7. DOCUMENTS SHOULD BE ANNEXED TECHINCAL BID a) GA drawing (in scale) with all details b) Time-bar chart (schedule chart showing the activities from receipt of P.O till

commissioning of crane at site SDSC SHAR) c) Documentary proof showing the experience of Vendor in this field

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ANNEXURE-1

SCOPE OF WORK:

1. The scope of work includes design, procurement of raw materials, manufacture, supply, erection, testing & commissioning of 30ton, flame-proof, EOT crane as per IS standards(IS:3117, IS807) and the given specifications, general conditions, and crane clearance diagram(Ref Figure-1).

2. Supply and installation of LT gantry Rails (Inclusive of all required accessories)

3. Supply and installation of power supply system and its accessories (Cable Drag chain system for CT & LT, Festoon system for Pendant Control)

4. The scope of work shall also include procurement of bought-out components

required for completion of the work, coordinated planning for manufacture, testing, painting, inspection, packing, loading on Trucks/ Trailers, safe transportation to site (SDSC SHAR), unloading and handling, erection, testing & commissioning as per Technical Specifications.

5. Engaging third party inspection agency and its expenses towards the same. 6. As the crane is intended to be used in hazardous area, the electrical switchgear

panels etc. should be of flame-proof in nature and control supply should include “Intrinsic safe package”.

7. This EOT crane will be used for highly critical activities and handling hazardous

materials and expensive hardwares. Hence design and realization of this crane shall be critical and the criteria to be followed and adopted shall be adhered to high degree of safety, reliability and quality for their systematic and proper functioning.

8. INSPECTION PLAN : Detailed inspection plan /procedure (Including Third Party

Inspection Agency’s role) shall be submitted by the supplier within 2 weeks from the date of P.O for approval from the Purchaser.

9. REPORTS TO BE SUBMITTED BY SUCCESSFUL VENDOR AFTER

GETTING P.O a) Detailed Inspection plan within 2 weeks from the date of P.O b) Design report within 1 Month from the date of P.O c) Test Certificates/Inspection Reports as per Annexure-8 before dispatch.

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ANNEXURE-2

TECHNICAL SPECIFICATIONS FOR 30 ton EOT CRANE

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ANNEXURE-2 A. TECHNICAL SPECIFICATIONS FOR 30 ton EOT CRANE

A.1 GENERAL : A.1.1 Capacity (Safe working Load) 30 ton A.1.2 Type of Crane Flame-Proof Type, Double girder, EOT crane A.1.3 Duty Class II (M5) Duty as per IS:807-2006 &

IS:3177-1999 with latest amendment for structure and mechanics

A.1.4 Working area classification Hazardous, Zone-1 Gas Group-IIB as per IS:5571, 5572 & 8239 Temperature Class: T4

A.1.5 Application Indoor A.1.6 Ambient Conditions Temperature:10 to 50 degree centigrade

Humidity: Maximum 95% A.1.7 Atmospheric condition Near sea shore (Saline Atmosphere) A.1.8 Span (Centre to centre of rails) 19m A.1.9 Hook Lift from ground level 14m (Including Rotary Limit & Gravity Limit) A.1.10 Height (Floor Level to rail top) 15m (Approximately for the assumed LT rail

height of 150mm) A1.11 Length of travel 60m A1.12 Hook Approach CT, LT To be provided by Vendor in GA drawing

which shall be Enclosed with Technical bid A1.13 Nature of load Loading & unloading, Lifting & handling of

Hardwares, tackles & fixtures. A1.14 Altitude of the place 10 m above mean sea level A1.15 Crane to be installed at New PS0 / PS0 XL Preparation Building,

at FLP Complex, VAST, SDSC SHAR, SRIHARIKOTA, A.P

A1.16 Number of crane One A.2 CLASSIFICATION :

Hoist CT LT Crane Structure

Class II as per IS 807-1976 (M5 As per IS 3177-1999) Class II as per IS 807-1976 (M5 As per IS 3177-1999) Class II as per IS 807-1976 (M5 As per IS 3177-1999) Class II as per IS 807-1976 (M5 As per IS 3177-1999)

A.3 OPERATING SPEED:

Type of operation Normal Creep LT 5.0 m/min 0.5 m/min CT 3.0 m/min 0.3 m/min Hoist 3.0 m/min 0.3 m/min

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A.4 COMPONENT DETAILS :

A.4.1 ROPE DRUM DETAILS:

a) Material Rolled steel Plates (OR) cast steel (Fabricated from IS 2062 material)

b) Diameter Minimum 18 times of wire rope diameter selected c) Length As per standard(IS 3177) for 14 m height of lift d) Flange/Flangeless Flanged at both ends e) Design Rope drum shall be designed as specified in

section 8.4 of IS 3177 – 1999 A.4.2 WIRE ROPE DETAILS:

a) IS code for Wire Rope Wire rope should confirm to IS2266/2002 b) Make USHA MARTIN c) Type of Wire Rope Non-Rotating Type d) Hot dip galvanized wire rope Type-B of IS1835-1976 e) Core IWRC f) Preformed or not Preformed g) Safety factor Greater than 6 h) Construction 34 x 7 (or) suitable construction required for

Non-rotating wire rope i) Tensile Strength 1770 N/mm2 (or) higher j) Diameter of the rope As per design requirement & standards

(section 8.3 of IS: 3177 – 1999 and IS 13870 : Part 1 : 1993)

k) Length of rope As per the requirement for 14 m height of lift l) Number of falls As required by the design. m) Regular/Lang’s lay Regular lay n) Right hand/left hand lay Right hand lay

A.4.3 SHEAVE DETAILS: a) Material Forged Steel b) Diameter of sheaves(main) 17 times of wire rope diameter

c) Diameter of sheaves (equalizer) 14 times of wire rope diameter d) Sheave guard

Rigid guards. Bottom block sheaves shall be enclosed except for wire rope opening

e) Design of Sheave As per section 8.5 of IS:3177 – 1999

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A.4.4 COUPLING DETAILS:

A.4.4.2 COUPLING BETWEEN MOTOR, GEAR BOX AND WHEELS: a) Type of coupling Flexible geared coupling b) Torque rating 300% of gear box output torque c) Size To be selected based on design

(Refer section 8.9 of IS: 3177 – 1999) d) LT & CT Couplings shall be used for connecting intermediate

lengths of LT and CT drive shafts, gearbox output shaft and intermediate shaft or end shaft.

e) Hoist For driving hoist drum, geared couplings shall be used between hoist rope drum and hoist gearbox out-put shafts.

f) Between intermediate shaft and end shaft and between end shaft and wheel axle, any other special coupling which can give better and more reliable service may be used after obtaining specific approval of the purchaser.

A.4.5 GEAR BOX / GEAR DETAILS:

a) Gear Box: All Gear boxes shall be provided with breather vents, oil level indicator and easily accessible oil drain plugs. Casing shall be two halves so that top half can be removed for inspection and repair without disturbing the bottom half.

b) Make As per Annexure-3 c) Classification Duty for class M5 as per Point No. 8.8.3 of IS 3177-

1999 d) Total No. of reductions As per design requirement e) Reduction ratio As per standards f) Type of lubrication Oil Splash lubrication for all gear boxes g) Gear Box Casing Material Cast steel/ fabricated & duly stress relieved before

machining (minimum 8mm thick). h) Bearings As per IS 3177-1999 point No. 8.7 i) KW rating As per design requirement j) Gear Box Noise level <85db at 1m away from the gear box.

This is very important for all the gearboxes and any gearbox making more noise is liable to be rejected.

k) Gears: Straight and helical spur gearing shall be used for all motions. Worm and bevel gears shall not be used without specific permission from purchaser. First and high-speed reductions shall be through helical gears. All gears shall be of hardened and tempered alloy or carbon steel with machine cut teeth. Gear teeth shall be preferably cut in metric module system. All gear teeth shall be ground smooth to give less noise while running. All gear shafts shall be supported on bearings mounted in gear box

l) Gear Material Pinions: Medium alloy steel suitably heat treated Gears: Medium alloy steel suitably heat treated

m) Hardness - BHN Pinions: 266 to 300 Gears : 217 to 255 (Difference of hardness of pinion & gear must not be less than 20 BHN)

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A.4.6 TYPE OF DRIVE ARRANGEMENT: Hoist Squirrel cage Induction motor with two EHT brakes(Imported), gear

box, Rope drum LT Central drive (Squirrel cage induction motor, gear box, LT drive shaft)

• Not less than 50% of the long travel wheels shall be positively driven unless agreed otherwise by the purchaser.

• All parts of the long travel drive shall preferably be located above the top platform.

• Shafts shall be easily accessible throughout their length and shall be designed as far as practicable inter-changeable lengths, the end and centre sections being as short as possible.

• The L.T. drive shaft minimum diameter shall be not less than 100mm. • The long travel drive shafts shall be supported on bearings at

approximately 3 m Centre or less. • Shaft couplings shall be as near as possible to the bearings. • Angular deflection of the line shaft at torque corresponding to 1.33

motor rated torque during acceleration shall not exceed 0.10 deg./m of shaft length

• In case of L.T. drive located at the span Centre, half the above torque, i.e. 2/3 of motor torque shall be taken for each half of the shaft.

• Driving pinions shall not interfere with the removal of wheels. CT Central drive (Squirrel cage induction motor, gear box, CT drive shaft)

• No part of cross travel drive shall be located below the trolley platform. Refer section 8.2 of IS: 3177 – 1999.

A.4.7 WHEEL DETAILS for LT&CT: (Double Flanged)

Long travel (LT) Wheel Cross travel (CT) Wheel a) Material Machined from Forged steel; C55 Mn75 (or) Similar b) Hardness 300-350 BHN 300-350 BHN

c) Depth of hardness 10 mm 10mm d) Diameter 400mm (minimum) 315mm (minimum) e) Design as per section 8.6 of IS:3177 – 1999

A.4.7.1 WHEEL LOAD: a) Minimum wheel load To be provided by the supplier based

on the design b) Maximum wheel load -do- c) Spacing of wheels -do-

A.4.8 LIFTING HOOK:

a) Type ‘C’ type b) Material Forged steel as specified in section 8.1 IS 3815 /15560 c) Safety latch on hook Hook latch to be provided

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A.4.9 TYPE OF BUFFERS: Spring type buffers shall be provided on both sides for CT and LT with phosphor bronze lining. Refer sec. 8.11 of IS: 3177 – 1999

A.4.10 BRIDGE GIRDERS: a) Type of girder Standard rolled sections (or) double web

plate box type construction. Sizes shall be as per design requirement.

b) Design of Bridge Girder Size, Length, width shall be in accordance with the latest edition of IS:807

c) Type of connection to end carriage Reamed bolt joint as per the design d) Girders shall be sufficiently strong and rigid to withstand the most severe

combination of loads that may develop under different working conditions. e) Numbers of splices to make up the requisite lengths for web and flange materials

of the girders shall not be more than 2 for girders up to 24m span and 3 for girders over 24m span

A.4.11 TYPE OF PLATFORM REQUIRED ON BRIDGE:

Platforms with toe-guards shall be provided for both CT girders (drive side, non-drive side) to the full span for attending maintenance works of crab wheel, and CT electric cable system.

Drive side platform shall be 750mm clear width fully covered with 6mm thick MS Chequered plates. Non-Drive Drive side platform shall be 1000mm clear width fully covered with 6mm thick MS Chequered plates. (Proper stiffening should be ensured for supporting chequered pates). Hand rails and toe guards shall be provided for both platforms.

A.4.12 MAINTENANCE CABIN:

A suitable size maintenance cage fixed to one of the bridge girder for accessing the LT electric cable system with suitable openings & ladder to reach the bottom level of the cabin shall be provided. Cabin opening shall be covered with suitable hinged doors. The cabin shall be minimum 1000 mm wide and shall be such that two persons can work comfortably in the space provided. The floor of the cabin shall be about 1500 mm below the L. T wheel centre.

Safe access for maintenance and removal of all mechanical and electrical parts

shall be ensured without any additional scaffolding or necessitating dismantling of other equipment or structures.

A.4.13 LUBRICATION: Individual grease nipples shall be provided for lubrication points on wheels &

bearing housings.

A4.14 BOLTS AND NUTS: All bolts, nuts, washers, etc. used in this crane shall be galvanized as per

IS 1367 Part-13 (Refer section 8.10 of IS: 3177 – 1999)

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A.4.15 SAFETY REQUIRMENTS: a) All the moving parts should be duly covered with guards as per safety norms.

Proper guard / cover / tray to prevent falling of bolts from coupling etc. should be provided, wherever required.

b) Coupling guards on all the drives should be provided. c) No cast iron parts shall be used on cranes except for electrical equipments.

Similarly wood or combustible materials should not be used in any part of the crane.

d) Safe working load indication plates shall be provided on both sides of double

girder and both sides of crane hook block.

e) Hand rails (Preferably in tubular construction) shall be provided in CT platform foot walks, end carriages, trolley, ladders and any other place where the access is required.

f) Hand rails shall not be less than 1000mm high with an intermediate member at a height of 500mm.

g) Approach ladders should be provided wherever required.

h) All edges or openings shall be provided with toe-guards. Toe angles or bent

plates wherever required shall be 100mm high minimum.

i) Safety devices/stops shall be fitted on the end carriages and trolley frame of Cranes to prevent derailment of crane, in the event of wheel or axle breakage. The safety devices shall be so fitted that they do not interfere with the removal of wheels.

j) Suitable jacking pads shall be provided on each end carriage and Double Girder

trolley frame of Cranes to facilitate replacement of track wheels without any interference

k) All electrical cables should be routed/laid through cable trays properly in such a

way that it should not be damaged and can be easily maintained and inspected. A.5 STRUCTURAL DETAILS :

A.5.1 Gantry Erection of LT gantry girder is in the scope of SDSC SHAR A.5.2 Rail & Accessories for CT&LT

• Scope of supplier: Supply & Erection of CT & LT rails.

• Size of rail: To be selected based on the design requirement.

• Rails ends shall be provided with stoppers to prevent over travel.

Rails made of rail steel shall be clamped to the girders with double bolt clamping plates spaced not more than 900 mm apart. Welded alignment blocks(both sides of rail) shall be provided between every two clamps such that the distance of a clamp from any adjacent alignment block shall not be more than 450 mm.

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A.5.3 DIMENSIONS: (Refer Figure-1 Crane Clearance Diagram, Page: 38) Span (Centre to centre distance between rails) (S) 19000 mm Height (or) lift of hook (H) 14000 mm (Including Rotary

Limit & Gravity Limit) Width of rail head (B) To be provided as called by

design Side clearance (X) = 500mm (Y)= 500mm Head Room Clearance (C) 3500mm Rail height from floor (D) 15000mm Position of hook from central line of rail for hoist

(E) (F)

1000mm 1000mm

Vertical clearance under side bridge (K) ≥14000mm A5.4 TROLLEY FRAME:

Trolley frame shall be produced in one piece unless there are transport limitations. Connection between the two parts of the trolley shall be done by machined bolts.

Drum bearings and supports for upper sheaves shall be located so as to equalize the load on the trolley wheels as nearly as possible.

The trolley frame shall be built up of rolled sections and plates to form a rigid structure capable of withstanding all stresses that will develop during the working of the crane and shall be arranged to afford maximum accessibility to mechanical and electrical parts place on it. The top of the trolley frame shall be covered all over except for openings required for ropes and flexible cables for bottom block etc. All the mechanical and electrical equipment shall be placed above trolley top plate as far as practicable. For any parts placed below the trolley top plate, access for maintenance, repair and replacement shall be provided. Handrails shall be provided on all the four sides of the trolley.

The trolley shall be fitted with substantial safety stops to prevent the trolley from falling more than 25 mm in the event of breakage of a track wheel, bogie or an axle. This safety stops shall not interfere with the removal of wheel.

The trolley shall be provided with lifting pads for jacking up the trolley in case of wheel removal. The jacking pads shall be at a height of about 300mm from the rail level and shall not interfere with the removal of wheels. A5.5 END CARRIAGES: End carriage shall be fabricated from rolled steel plates, welded together to form as box section. End carriages shall be rigidly connected to the respective bridge girder. End carriages shall be of ample strength to resist all stresses likely to be imposed on them under service conditions, including collision with stops. Length of the end carriages shall be such that no other part of the crane is damaged in collision.

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The wheel base shall not be less than 1/5th of span. Wheel base shall be taken as the distance between the centers of the outside wheels. The end carriages shall be fitted with safety stops to prevent the crane from falling more than 25mm in the event of breakage of a track wheel, bogie or axle. These safety stops shall not interfere with the removal of wheels. Suitable jacking pads at a height of 300mm from rail level shall be provided on each end carriage for jacking up the crane when changing track wheels. Jacking pads shall not interfere with the replacement of track wheels. A5.6 GENERAL:

a) For welded construction such as bridge girders and carriages, trolley frames, rope drums, gearboxes etc., (all steel plates) shall conform to IS-2062 or its equivalent.

b) Defects in the material like fractures, cracks, blow holes, laminations, pitting, etc., are not allowed. Rectification of any such flaw is permissible only with the approval of the purchaser or inspection agency Engineer.

c) Crane structures shall be designed in accordance with the latest edition of IS:807 taking the following additions / deviations as applicable into account

d) Unless otherwise specified, only bolted or welded joints shall be used. e) All the bolts, nuts, washers etc., shall be heavy duty galvanized. f) The calculated strength of riveted joint or joints made by friction grip bolts in

structural members shall be not less than calculated net strength of the member. g) Transverse fillet welding on load carrying members shall be avoided. h) All butt welds on structural members subject to tensile stress shall be X-ray

tested. i) Plates, bars, angles and where practicable, other rolled sections used in the load

bearing members of the structure shall be not less than 8 mm thick. Steel tubes, if sealed at the ends shall be not less than 4.9mm (6 SG) thick and if unsealed, not less than 8 mm thick.

j) Minimum thickness of chequered plates for platforms shall be 6mm over plain for indoor cranes. Chequered plates shall not be considered for strength calculations of load carrying members.

k) The ratio of the effective length ‘l’ to the least radius of gyration ‘r’ for compression members shall not exceed 120 for all main members i.e., for both the main and auxiliary girder members and top and bottom plan bracings and 180 for secondary members.

l) Splice shall be designed to resist all the forces and moments to which it is subjected to plus 50% thereof. However, in no case the strength developed by the splice shall be less than 50% of the effective strength of the material spliced. Splices shall be proportioned and arranged, so that the gravity axis of the splice is in line with the gravity axes of the members jointed so as to avoid the eccentricity of the loading.

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A.6 PAINTING: a) Surface preparation Sand/ steel grit blasting confirming to SA 2½ shall be done

for cleaning the fabricated surface of all steel structural members. After sand/steel grit blasting, all the surfaces shall be cleaned & free from dust moisture, oil, etc.

b) Prime coat Inorganic Zinc rich epoxy primer shall be applied to a dry film thickness (DFT) of 75 microns minimum.

c) Intermediate coat An intermediate coat of 80 micron (DFT) of polyurethane/epoxy painting has to be applied.

d) Finishing coat Polyurethane enamel paint (Golden Yellow) to a DFT of 50 microns (minimum) shall be applied.

e) Make As per Annexure-3 f) The contractor shall provide “ Elicometer”/ Paint Thickness measurement gauge

to the representative of the purchaser for measuring the paint thickness at random locations selected by him to confirm the required minimum DFT.

g) Interior of all gear box housings shall be sand blasted and painted with two coats of oil resisting enamel paint.

h) All machine pads, bearing surface on structures or housings shall be painted with white lead.

i) Inner surfaces of box sections shall be painted before closing them. All parts inaccessible after assembly shall be painted before the assembly.

A.7 SPECIAL TECHNICAL REQUIREMENTS :

a) General drawing To be provided by the supplier b) Total self-weight of the crane c) Weight of girder and platform d) Weight of end carriage with wheels e) Weight of the trolley f) Trolley frame g) Crab arrangement h) Weight of maintenance cabin i) Type of festooned cable system j) Permissible No. of starts per hour 300 starts/hour k) Approved makes for bought-out items As detailed in Annexure-3 l) Central drive torsional rigidity of the

Transmission shaft < 0.1 deg./m length for LT & CT

m) Torsional limit LT & CT drive axles shall be designed, checked for torsional rigidity as per IS standards

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A.8 ELECTRICAL DETAILS

A.8.1 SCOPE OF SUPPLY:

The scope of supply shall cover all items of electrical systems commencing from main cable. The crane electric include power disconnecting switch on the crane bridge walkway, protective switch gear, motors, motor control panels, brakes, limit switches, power and control cables, socket outlets, lighting distribution panel and lighting fixtures, with lamps, DSL, indicating lamps, push buttons and equipment earthing material. All sundry erection material required for installation and connecting up of electrical equipment with cable laying and fixing accessories.

A8.2 TYPE OF ELECTRCIAL EQUIPMENTS: This EOT crane is intended to operate in Hazardous environment as per the hazardous area classification Zone-1, Gas group-IIB, T4 as per IS5572. Hence all the electrical equipment, limit switches and controls offered shall be Flame-Proof type and suitable to operate in the above environment as per relevant Indian standards (IS 5571, IS2148, IS 5780) and IEC standards (IEC 60079).

A.8.3 POWER SUPPLY AT THE CRANE LONG TRAVEL COLLECTORS:

Voltage AC, 415V nominal ± 10% No of phases 3 Frequency 50 Hz ± 3% No of conductors 4 Neutral As per the circuit requirement. All electrical components used shall be suitable for the above power supply system

A.8.4 SELECTION OF RATING OF ELECTRICAL COMPONENTS:

1. Power cables All power cables shall be 1.1KV grade and current rating is approx 50% more than the size arrived at by normal design

2. Switch gears Current rating shall be approx 50% more than the rating arrived at by normal design but fuse rating as per requirement.

3. Contactors Current rating shall be approx 50% (minimum) more than the rating arrived at by normal design but fuse rating as per requirement but over load relays shall be as per motor rating.

A.8.5 CONTROLS:

a) Pendant Control 1) Crane should be controlled from ground by means of pendant push button controls

2) Push button type with IP-55 protection in stainless steel enclosure

3) Indicating lamps for power and control ON shall be provided

4) Emergency switch shall be provided on the pendant to cutoff control power supply.

5) Pendant shall be provided with lock & key provision for ON/OFF to prevent inadvertent

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operation. 6) Push button shall be provided for under bridge

lights ON/OFF. 7) DSL for the pendant shall be festooning cable on

independent “T” track along the span of the bridge girder on four wheeled cable trolley with anti-friction ball bearing.

8) Each trolley shall be provided with buffers to avoid cable entanglement

9) Tension coming on the cables due to trolley movement shall be avoided by providing stainless steel chains between the trolleys.

10) The pendant shall be suspended by a suitable SS chain/ PVC coated wire rope so that control cable is free from loading.

b) Control circuit 1) 7.5V / std “intrins ic safe circuit” should be used confirming to IS:5780 and suitable for the flame-proof category.

2) Normal conventional contactor logic control system shall be provided.

3) Control power has to be derived from suitable rated control transformers located inside each group of controls like CT/LT/Hoist.

4) All indications lamps are of LED type. c) Scheme of hazardous

class of protection All the control and power panels/switches shall be group IIB Exd flame-proof enclosure

d) Requirement of isolation switch and its position

One isolation switch shall be provided on the bridge at the point of entry of DSL on to the bridge. Isolation switch for incoming supply at 1m ht from ground level will be provided by SDSC SHAR

A.8.6 MOTOR DETAILS: (For Hoist, CT and LT)

a) Motor Type Flame-Proof (as per IS:2148), squirrel cage, crane duty induction motor

b) Approved manufacturers for motors

As per Annexure-3

c) Class of insulation & Protection

Class ‘F’, IIB enclosure and temp limited to Class B

d) Duty classification S5 e) No. of starts 300/hr with 40% CDF f) Temperature classification T4 (135 Degree) or better g) Frame size As required by the design h) Speed As required by the design i) KW rating As required by the design

(Rating of motor shall be 20% excess of the capacity calculated as per IS:3177)

j) Motors selected should not draw more than 80% of the rated full load current for the full load operations at 415V AC

k) For side alignment of motors strong adjustable screws with lock nuts shall be provided.

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A. 8.7 BRAKES: Hoist CT LT a) Type Flame-Proof Electro Hydraulic Thruster brakes (EHT)

b) Diameter of brake As per standard hoist design 250 mm (min)

As per design As per design

c) Torque rating 200% of full load motor torque (FLMT)

200% of FLMT 200% of FLMT

d) No of brakes (i) Normal speed:

Two Brakes (Main + Redundant )

One Brake

One Brake

(ii) Creep speed: Two Brakes (Holding + creep)

Two Brakes (Holding + creep)

Two Brakes (Holding + creep)

e) Brake shall be mounted on the input pinion shaft of the gear train. The brake shoes shall be of hinged type. Brake levers shall be forged or fabricated or cast steel. Hinge pins shall be of hardened alloy steel and shall be lubricated. These hinge pins shall be provided with steel bushes at bearing point. Brake drums shall be forged or of cast steel. Drums shall be completely machined and dynamically balance. Width of the brake drum shall be 5 to10mm more than the width of the brake shoes. Hardness of brake drum shall be 38 – 43 Rc. No oil leakage is allowed from thruster brakes. Braking path shall be calculated as per IS3177.

A.8.8 LIMIT SWITCHES:

Limit switches shall be heavy duty type with protective enclosure of IP 55 as per IS 2147. For flame-proof cranes limit switches shall be heavy-duty type and shall be wired in the Intrinsic Safe circuit to operate in hazardous environment Zone 1, Gas group IIA/IIB.

Hoisting Heavy duty Rotary type(Up & Down) 1 No. Make: As per Annexure-3

Heavy duty Gravity type (Up) 1 No. LT Heavy duty two way Lever type 1 No. CT Heavy duty two way Lever type 1 No.

A.8.9 TYPE OF CT & LT Electric Cables: CT, LT Power supply Arrangement

Cable “Chain Drag System”

CT, LT, Hoist Electric Cable arrangement

Flexible cables with multi strand copper conductors suitable for cable “chain drag system”.

Incoming cables

a) Suitable, copper conductor, PVC/XLPE insulated, armoured cable from bottom incoming switch to top junction box (Approximately 100 mtr)

b) Suitable size flexible cables with multi-strand copper conductor cable suitable for “chain drag system” from junction box to panels.

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A.8.10 EARTHING: a) The crane structure shall be made continuous by providing jumpers over

riveted or bolted joints and the structure is earthed through the fourth set of main collectors and earth lead. The fourth conductor of down shop leads shall be earthen at both ends and serves as the earthing lead to the crane.

b) Double earthing shall be provided to all the electrical equipments on the crane such as motors, thrusters, panels etc.

c) Rails, structures, motor frames, metal enclosures, conduit shall be effectively grounded.

d) Copper flats of required size shall be used for grounding. Crane grounding shall be connected to main grounding at ground level.

e) Flexible cables shall have a separate earth core serving as earth lead for satisfactory earth connection of equipments.

f) Along with pendent control cable an additional wire braided flexible copper strip of 12mm wide shall run as a special earth from the control panel up to the pendent station.

A.8.11 AUXILIARY ITEMS:

Under Bridge Lighting

• 4Nos. of, flame-proof, 250W, Metal halide, Highbay/suitableType, standard and approved brand light fittings with MCB control shall be provided below the crane to illuminate the working area.

• Push button shall be provided for lights ON/OFF. • These light fittings should be provided with wire mesh

and glass to avoid free falling of lamp. • Light fittings should be shock absorbing & anti swing

suspension, mounted firmly to the bottom of the bridge girder.

Socket points 32/16 amps, single phase, flame-proof socket with top (1No.) 32amps, 3 phase+N, flame proof socket with plug top (1 No.) With control shall be provided on the crane for facilitating temporary power tapping for maintenance works.

A8.12 CONTROL PANELS:

a) All power and auxiliary contactors, individual overload relays, etc., shall be mounted in flame-proof enclosures. Flame-proof enclosures used for panels shall be of cast iron/cast aluminum suitable for Group IIB hazardous area covered under IS5572 and should confirm to IS2148 with IP56 protection as per IS2147.

b) All the contactors etc., shall be mounted securely in a vertical arrangement with due consideration to the vibration encountered in the operation of crane.

c) Terminal strip shall be fixed inside the panel preferably in horizontal manner leaving enough space underneath the panel for termination of cables in a convenient manner.

d) All equipment inside the panel shall have permanent identification labels in accordance with circuit diagram as also the power and control terminals. Suitable ferrules shall be provided inside the panels at the ends.

e) All control panels shall be well braced to the crane structure and each panel shall be provided with adequate number of lifting lugs.

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A8.13 CONTACTORS: Contactors rating shall be fixed taking into account the rating of the Motor used, and

relevant duty cycle. After taking into account all the above factors, a cushion of at least 50% shall be built into the rating of the contactor. The minimum size of contactors on the power circuit shall be rated for 30 amps. The contactors shall be able to withstand 15 times their rated current for one second without welding of the contactors. All contactor shall be AC duty only, and OLR for hoist shall be CT operated.

A8.14 CIRCUIT PROTECTIVE SWITCHGEAR: The protective switchgear shall consist of One triple pole TPNSFU with HRC fuses/Fuse less feeder like MCCB/MCB, rated to

carry at least combined full load currents of the two motions on the crane having largest power (KW). In coming supply for each motion shall be through one individual triple pole off load isolations for the purpose of isolation and checking of control functions. These isolations shall be mounted in the respective panels. A.8.15 IDENTIFICATION OF CIRCUITS, CABLES ETC.

Permanent Labels shall be provided on supports of all switches, fuses, contactors, relays etc., to facilitate identification of circuits and replacement. All panels are to be properly marked for each motion. All power control cables, lighting and other cables are to be tagged at both ends as per cable number indicated in the supplier’s drawing. All equipment terminals are also to be marked likewise.

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ANNEXURE-3 B. LIST OF MANUFACTURERS / SPECIFIC BRANDS FOR BOUGHT-OUT ITEMS: S.No. Item Name MAKE B1. Gear boxes Elecon / Allroyd / New Allen berry / Shanti / Nutech / crane

manufacturer’s make (If manufacturer is supplying his own make, he has to follow the manufacturing process as given in Annexure-5)

B2. Wire ropes (all galvanized)

Usha Martin

B3. Bearings SKF, FAG, NSK, TIMKEN B4. Couplings Fenner, Elecon, Radicon, Shanthi, Love-joy B5. Paints Bombay paints, Berger, Asian, Shalimar, Jenson &

Nicholson, Nerolac, Dulex, Polycoat B6. Power supply

components Siemens

B7. Power & control cables

Incab, Cable corpn of India, Universal, Nicco, Asian, Finolex, Polycab

B8. Electric Motors (Flame-Proof)

Kirloskar, Siemens, Best & Crompton, Bharat Bijilee, Crompton Greaves, Hindustan motor, ABB etc

B9. Electro Hydraulic Thruster Brakes (Flame-Proof)

For Hoist: Imported Make: Witton Kramer, Bubenzer, Sibre. Thruster Make:ELHY For CT&LT : Indigenous Make: Elektromag method(EMM), Sterling control

B10. Limit switches (Flame-Proof)

Speed-o-control, Electromag(EMM), Stom kraft, Siemens

B11. Push button Siemens B12. Flame-proof panels,

Light Fittings, Glands, Junction boxes & Enclosures

Baliga, FCG

B13. Intrinsic safe Barrier Peperl & Fuchs(P&F), MTL B14. 415V Switch Gears

Contactor, Relay MCB, MCCB, OLR etc.

Siemens

B15. Cable Drag chain system (for CT & LT)

IGUS or Similar

Note: Supplier should get prior approval from the purchaser for any other make of bought-out items other than the one indicated above. The purchaser reserves the right to reject any other make.

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ANNEXURE-4

GENERAL CONDITIONS

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ANNEXURE-4

C. GENERAL CONDITIONS FOR 30ton EOT CRANE

C1. GENERAL ARRANGEMENT DRAWING : Offer/Tender shall be enclosed with general arrangement drawing (to scale)

showing the elevation, cross section and plan of the EOT crane which shall indicate the information viz., clearances, construction of bridge structure, hook approaches, lift, wheel base, wheel loads and diameters, motor ratings, speeds, arrangement of all the drives and other equipment installed on the crane.

Also the vendor shall confirm all the specifications point by point as detailed in the technical specifications A1 to A8 (Annexure-2). Tenders shall be rejected, if compliance with this clause is not ensured. Vendor shall clearly specify any request for deviation from technical specification on particular items. Note:

Generalized statements like crane shall be manufactured as per IS standard and our specifications etc. are not adequate. The identification number of applicable standards shall be clearly mentioned. The reference number of applicable, standards shall be clearly mentioned. Otherwise, it may result in rejection of the tender.

C2. TIME BAR-CHART FOR FABRICATION SCHEDULE :

Vendor shall submit a time-bar chart along with tender indicating starting and completion dates of each activity such as design, preparation of drawings, procurement of materials, fabrication, machining of components, assembly etc., without which the tender may not be considered. The schedule bar chart shall form a part of the order and cannot be altered arbitrarily by the supplier except for force-majeure conditions or the reasons attributable to the purchaser.

C3. DRAWING APPROVAL & DESIGN CLEARANCE FOR FABRICATION :

• After receiving the purchase order (P.O), supplier should submit a “Detailed Design Report” (three copies) to the purchaser and third party inspection agency for review, comments and approval prior to the commencement of fabrication.

• Design of the crane has to be cleared by the purchaser (SDSC SHAR) before taking up the fabrication works. Design report should consist of following drawings, design details and design calculations: a) General arrangement (GA) drawings containing all information as described

in C1. In addition to this, the GA drawing shall clearly show the layout of

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electrical panels, resistance boxes, transformers, etc., All the dimensions and clearances shall be clearly marked in the drawing.

b) General layout drawing of the trolley.

c) Assembly drawings of individual drives like hoist, long travel, cross travel etc.

subassembly drawings for wheels, hook block and hoist drums.

d) Pendant layout with its components shall be approved by the department.

e) Electrical schematic diagrams/wiring circuit diagram for total crane containing details of components such as make, type, rating/range, settings etc., are to be marked on the schematic diagram. All contacts and coils of contact shall be numbered/ designated.

f) Torque speed curves of individual motors.

g) Cable sizes & type selected for different current ratings.

h) Design calculations for all motions, structures showing the maximum stresses

and the permissible stress of the individual constructional member and connections against the load conditions, particularly the connection of the bridge girders to the end carriage and splice joints etc.,

i) Deflection calculations

j) Detailed structural drawings for the bridge girders, end carriages, repair cages,

inspection platforms, trolley frame etc.,

k) Calculations and drawings for other structural, mechanical or electrical component such as intermediate shafts, couplings, bearings, wheels, gears, hooks, rope drums, sheaves, cross conductors, motors, brakes, and other control equipment shall be provided.

l) Makes of all components like, flame-proof electrical motors, electrical motors

intrinsic controls, flame-proof thruster brakes, limit switches etc., shall be provided.

m) Details and specifications of bought-out materials, components.

n) Quality plan

o) Note: The successful Vendor may visit the site SDSC SHAR (if required) to

measure all necessary dimensions i.e. Span, Head Room, Power supply system, rail size etc., at site before starting of the crane design /manufacturing.

C4. All the above mentioned drawings, design report (design calculations) required for the

approval shall be submitted to the purchaser and third party inspection agency within 1 month from the date of Purchase order (P.O).

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C5. If any drawing/design calculations (submitted by the supplier after P.O receipt) found incomplete or faulty it will be returned by the purchaser. Supplier shall make necessary corrections / modifications and resubmit the drawings and calculations within a reasonable time but in any case should not exceed two weeks from the date of receipt of comments either from purchaser/third party inspection agency.

C6. The granting of any approval by SDSC, SHAR shall not absolve the CONTRACTOR of

his responsibilities for the design or the correctness of drawings and specifications. Any such approval by SDSC, SHAR shall not constitute a waiver by SDSC, SHAR of any right.

C7. Supplier shall give the break-up of weights of the crane as mentioned below in the final

design / fabrication drawings.

S.No. Description Weight 1. Total weight of crane including electrical equipment To be given by supplier 2. Total weight of trolley including electrical

equipment -do-

3. Weight of each bridge girder as assembled and ready for erection, with and without mechanical and electrical components

-do-

4. Weight of each end carriage as assembled and ready for erection

-do-

5. Weight and name of individual heaviest mechanical components

-do-

6. Total weight of structural, mechanical and electrical components separately

-do-

C8. CERTIFICATION OF CRANE HOOK

The crane hook should be certified by the dock labour board / govt. approved test house for twice its SWL and relevant test certificate should be provided.

C9. The contractor shall submit test certificates for all electrical equipment, cables and all

parts used in handling loads such as wire ropes, chains, load hooks etc., C10. The contractor shall submit material test certificate for structural steel and materials

used for mechanical components such as couplings, gears, gear boxes, ropes drums, brake drums, pulley, shafts, wheels, crane rails, etc.,

C11. Dimensions of all parts used on crane shall conform to metric standards.

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C12. The contractor shall ensure that the cranes shall be manufactured as per the tolerances specified below. a) Span over L.T wheel ± 4mm up to 21 meters maximum b) Diagonal on wheels ± 5mm maximum c) Long travel wheel alignment ± 1mm maximum d) Tilt of wheels or balancer ± 1mm / 1000mm maximum

( horizontal & vertical) e) Trolley wheel gauge ± 2mm for gauge up to 2.5mm (maximum)

± 3mm for gauge over 2.5mm f) Difference in height between

trolley rails (H) in relation to the trolley track gauge (S) shall be within the following tolerances

“ S” (mm) up to 2500 above 2500

“H” mm 3 5

g) Speeds at full rated load, voltage, and frequency shall be as follows: I) Traveling & traversing : +10% -5% of specified speed. II) Hoisting : +10% -5% of specified speed. III) Lowering : +15%-5% of specified speed.

C13. INSPECTION at SUPPLIER’S SITE BEFORE DESPATCH:

1. The crane shall be inspected and tested during different stages of its designs,

manufacture starting from raw materials stage till the completion of the crane, by the third party inspection agency. Inspection shall be regarded as a check-up and shall be in no way binding on the purchaser.

2. Engagement of Third Party Inspection Agency: Supplier should engage Third Party Inspection Agency (INSPECTORATE) for carrying out design verification/raw material inspection/stage inspection/final inspection/erection, testing and commissioning. Responsibility of Third party inspection agency shall start from design verification till commissioning at SDSC SHAR. Contractor shall extend all necessary help/ equipment/ tools/ measuring instruments as required for carrying out necessary tests/ inspection at works/ site to the representatives of SDSC, SHAR / INSPECTORATE.

3. Cost towards the third party inspection shall be borne by the supplier and shall be included in the offer.

4. Third party inspection agencies shall be M/S Loyds register, M/S Mecon, M/S M.N.Dhastur, M/S BVQI and DET NORSKE VERITAS (DNV) only. Any other reputed inspection agencies shall be duly approved by the purchaser.

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5. Inspection/Follow-up by Purchaser: SDSC, SHAR/INSPECTORATE shall have the right of inspection and supervision of the manufacturing process adopted by the Contractor for the manufacture of equipment at various stages through their authorized representatives. In case the manufacturing process adopted is not found suitable and commensurate with the desired quality of the equipment, the Contractor will be advised to adopt the correct manufacturing process which will be binding on the Contractor. SDSC, SHAR’s decision regarding the quality of work and its acceptability shall be final and binding on the Contractor.

6. Intimation / Call for Stage Inspection: Supplier shall call for stage inspection as per the inspection plan. The Supplier shall intimate in advance to SDSC, SHAR/INSPECTORATE for inspection and testing of any equipment.

7. Periodic Inspection by Third Party & Purchaser:

Arrangements shall be made by the contractor for the inspection and testing of the crane during different stages of its manufacture starting from the raw materials till completion of the crane at supplier’s site as per the following schedule. Purchaser will also participate in the inspection, if he so desires whenever third party inspection is identified.

a) Design verification b) Raw material identification, components like gears, shafts, keys, keyways sub

assemblies of drive mechanism mechanical and electrical. c) Grinding of gear teeth after surface hardening. d) Use of grinding paste for planetary gear should be avoided. If used, thorough

cleaning after the use. No grinding paste to go to the bearings. e) Proper oil seals for shafts of gear-boxes. f) Alignment of Motor shaft, gear box shaft, brake unit etc., g) Proper adjustment of brake shoes for optimum braking. Hoisting motion twin

brakes – each should be adjusted independently to take the full load. h) Measurement of noise level in db. (should be <85 db at 1 m away from gear box). i) Paint thickness measurements at various stages like primer, intermediate and

final coats. j) Radiographic / ultrasonic inspection of the critical weld joints of the girders, rope

drums, end carriages etc. k) The crane shall be tested in all respects in conformity with section 4 of IS 3177-

1999 in the presence of the purchaser or his representative before dispatch. The manufacturer shall submit detailed list on the item/tests to inspection agency and shall provide the necessary testing facility (equipments such as noise measurement, paint thickness measurement) for the inspecting engineers during the test.

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C14. LOAD TESTING AT SUPPLIER’S SITE PRIOR TO DISPATCH: The crane shall be completely assembled including wiring and other fittings in the supplier’s site before load testing of the crane. Load Testing should be done at supplier’s site prior to the dispatch. The test shall include no load, full load and 125% overload, insulation test, speed test, deflection test, etc. Crane hoist and traverse shall be tested to its rated load and over load. Necessary loads for load testing should be arranged by supplier.

C15. Following documents should be supplied prior to commissioning of the crane:

a) Four copies of all drawings and data which have been approved by the purchaser. b) Four copies of the following manuals/ drawings shall be submitted.

i) Operating manuals. This shall include write-up on electrical control also. ii) Maintenance manuals. iii) Lubrication charts. iv) Electrical circuit schematics. v) A consolidated list of electrical equipment indicating make, type, rating, settings

etc., vi) External electrical wiring diagram. vii) Cable routing diagrams showing cross sectional details and clamping / fixing

arrangement of cables etc. viii) Any other special features. ix) Catalogues of all electrical equipments and drawings mechanical spare part (i.e.

Gears, Wheels, drum, drive shafts) etc In addition to the hard copy of the above documents, supplier shall hand over a

CD/DVD for the crane containing all drawings, design documents, plan and procedures, operation and maintenance manuals.

C16. ERECTION & COMMISSIONING : The crane shall be erected, tested and

commissioned at our site (SDSC SHAR). Commissioning includes erection of LT rails on girder and checking the satisfactory performance of crane with load.

C17. Quantum of work at Site During Erection & Commissioning (SDSC SHAR):

The contractor shall ensure that only minimum amount of assembly at site is necessary for early commissioning of the crane after delivery. Site welding shall be as minimum as possible. The contractor before proceeding with design details shall satisfy himself about the site condition so as to avoid any difficulty in erection due to peculiarity of site condition.

C18. Alignment of LT Rails on Gantry Girder : LT Rails should be aligned properly before erection of crane. Parallelism should be maintained between rails over the full length (60m) of rails. Derailing of wheels shall be avoided by ensuring proper rail alignment.

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C19. Load test at Purchaser’s site(SDSC SHAR): Necessary loads for load testing will be provided by SDSC SHAR. The crane after erection at purchaser’s site SDSC SHAR shall be tested as given below:- a) No load Test:

After completion of erection, crane shall be tested with no load to check the performance of crane speeds, end clearance, hook approaches, height of lift, limit switch operations, no load current of motors, contacts, relays, inter locks etc.,

b) Deflection Test:

Deflection of the bridge girders shall not exceed 1/1000 of span with the fully loaded trolley stationed at mid-span and the safe working load at rest. Measurement shall not be taken on the first application of load. The datum line for measuring the deflection should be obtained by placing the unloaded trolley on the extreme end of crane span.

c) Speed Tests:

1) Rated Load Test: All the motions of the crane shall be tested with rated load and the rated speeds shall be attained within the tolerance limits indicated under clause C12(g).

2) Overload Test: All the motions of the crane should be tested with 25% overload (1.25 times of rated load) in which case the rated speeds may not be attained but the crane shall show itself capable of dealing with the over load without any difficulty.

c) Performance Tests:

The cranes shall be tested with rated load for performance of long travel and cross travel motions to develop the required acceleration.

d) Brake Tests: 1) The hoists brakes shall be capable of breaking the movement under conditions (1)

& (2) of speed tests, however the braking path with rated load shall not exceed the value specified in IS standard.

2) The long travel and cross travel brakes shall be capable of arresting the motion within a distance in meters equal to 10% of the speed in meters / minute and the retardation due to braking shall not exceed the values as given in IS standard.

3) Insulation and other tests as mentioned in IS:4137 shall also be carried out.

C20. Points To be Taken into account for Quotation:

Vendor shall quote separately for erection, transportation and unloading at site (SDSC SHAR) by their own men, material, tools and tackles. The crane shall be transported at supplier’s risk and cost. The purchaser will not pay for any insurance.

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C21. Excise duty exemption certificate will be provided by the purchaser. Hence this shall be taken into account for quotation.

C22. Completion Period for Delivery & Commissioning:

The Party should supply all the items & complete the commissioning of crane at our site in all respects within 8 months from the date of Purchase Order. The delivery schedule is one of the main parameters considered for the evaluation of the offers.

C23. Guarantee: The crane should be guaranteed for a period of 1 Year from the date of

acceptance/commissioning against defects in design, material and workmanship. Any defects noticed during the guarantee period shall be attended by the supplier at free of cost at purchaser’s premises.

C24. Performance Bank guarantee for 10% of the cost of the crane shall be provided by the contractor for the guarantee period i.e., for a period of 1 year from the date of commissioning and acceptance of the crane at purchaser’s site at Sriharikota.

C25. The transfer of title to the purchaser will take place only after satisfactory erection,

testing and commissioning of the crane by the contractor and acceptance by the purchaser. Hence, any insurance charges are to be borne by the contractor.

C26. During the erection, testing and commissioning of the crane at site in Sriharikota, the

contractor has to make his own arrangements for boarding, lodging, transportation of his men and materials. However, hostel accommodation may be provided by the purchaser on chargeable basis, if available.

C27. No material handling equipments like, mobile crane, forklift, BOT etc. will be provided

to supplier during erection and commissioning. Supplier has to make his own arrangements for unloading & handling of items at site (SDSC SHAR).

C28. Supplier shall make own arrangement for welding & gas cutting works(If any) at SDSC

SHAR

C29. The purchaser will provide free electricity and water for the erection, testing and commissioning of the cranes at the site(SDSC SHAR)

C30. Insurance for working Personal: Before starting the site work, the contractor has to

insure all his personnel working at site in Sriharikota against accidents. C31. Liquidated Damages (LD):

The delivery period is very critical for this crane. LD at the rate of 0.5% per week of delay or part thereof on the cost of the crane subject to a maximum of 10% of the total cost of the cranes will be imposed, if the causes of the delay are attributable to the contractor or his vendors.

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C32. Sufficient quantity of lubricants (Grease & Oil etc.) required for (Initial filling) commissioning at site SDSC SHAR shall be provided by the supplier. The cost of the same shall be included in the offer.

C33. TOOL-BOX

A tool-box containing all necessary tools like torque wrench, portable hydraulic jacks, hand grease gun, set of spanners, screw drivers etc., required for the maintenance of the crane, shall be supplied with the crane and the price of the same shall be included in the quotation separately.

S.No. Item Name Quantity (Nos.)

Price

1. Portable Mechanical Screw Jack/ hydraulic jack 1 2. Hand Grease gun 1 3. Hand Oil Can 1 4. Free Spanners 2 5. Spanners set 1 Set 6. Screw driver 2 7. Hammer 2 8. Any other essential items -- 9. Tool box for Sotring above tools 1

C34. Vendor shall quote separately for spares as considered necessary by him, for two years

of normal operation of the crane. The list of spares shall be quoted separately with price break up for each item as shown below.

S.No. List of Spare Quantity Price 1. Thruster for Hoist 1 No. 2. Thruster for CT & LT 1 Each 3. Overload Relay (OLR) 1 set 4. Intrinisic Safe Relay 2 Nos. 5. Contactor (for Each motor) 1 set 6. Gear Box oil 30 Litre 7. Wire Rope for main hoist 1 Length 8. Bearings for Sq. Cage Motors used

each type motor used in crane 1 set

9. Oil Seals for Gear Boxes (Each type used in crane)

5 Set

10. Contacts for limit Switches (Each type used in Crane)

6 Set

11. Brake liners for brakes (Each type used in Crane)

5 Set

12. Push Button Elements 6 Set 13. Any other essential spares

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C35. VALIDITY OF OFFER : The quotation should remain valid for a minimum period of six months from the tender due date.

C36. HOW TO QUOTE ? 1. ONLY PARTIES HAVING ENOUGH EXPERIENCE IN FABRICATIO N

AND SUPPLYING OF SIMILAR ITEMS NEED TO QUOTE. THEY SHOULD SUBMIT DOCUMENTARY EVIDENCES AND LIST OF CUSTOMERS TO THIS EFFECT ALONG WITH THE OFFER. OFFE RS WITHOUT THESE DOCUMENTS WILL BE SUMMARILY REJECTED.

2. Parties should quote in two parts viz.,

Part – I Technical and Commercial bid. Part – II Price bid.

3. PART-I TECHNICAL & COMMERCIAL BID :

This part should contain detailed specifications of the item, scope of the work and confirmation of the Vendor in meeting every condition specified in the tender. Any deviation from the condition shall be clearly brought out. It shall be noted that the offer may be rejected, if unacceptable deviations are put forth.

All the commercial terms and conditions applicable also should be indicated separately under separate heads, under this bid. The commercial terms such as delivery terms, delivery period, payment terms, guarantee, validity of the offer, duties and taxes etc., shall come into this.

Please note that prices should not be indicated in this part.

Technical & commercial part prepared as described above shall be enveloped, sealed, super scribed and addressed as given below:

TENDER NO : DUE DATE : PART-I : TECHNICAL & COMMERCIAL BID TO THE PURCHASE OFFICER,

RANGE PURCHASE, KEEPAKAM, SDSC SHAR/ISRO, SRIHARIKOTA – 524124 NELLORE DIST., (A.P.)

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4. PART-II: PRICE BID: Format for price bid (Part-II) is enclosed in ANNEXURE-7 for reference. Party shall quote the prices in the format.Only prices applicable for the items, in response to the tender shall come into this part. Vendor shall indicate very clearly the prices with reference to their technical offer. Price part prepared as above shall be enveloped, sealed, super scribed and addressed as given below: 5. Two separate envelopes i.e a) Technical & commercial envelope (Part-I),

b) Price envelope (Part-II) prepared as above should be inserted in another envelope, sealed, super scribed and addressed as given below:

TENDER NO : DUE DATE : PART-I : PRICE BID TO THE PURCHASE OFFICER,

RANGE PURCHASE, KEEPAKAM, SDSC SHAR/ISRO, SRIHARIKOTA – 524124 NELLORE DIST., (A.P.)

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ANNEXURE-5

D. Supply requirements for providing Crane supplier’s gearboxes for EOT cranes:

If the supplier is not in a position to provide a standard gear box of reputed gear box manufacturer’s and the same gearbox can be own product of the supplier. In such case the supplier shall meet the following technical requirements and conditions:

D1. The supplier shall submit an overall plan for design, manufacture and testing of gearbox

and related standards followed. Gearboxes shall be designed, manufactured and tested as per API 613/AGMA 6010 standards and suitable for crane duty. This information shall be furnished along with these clarifications.

D2. After receipt of order and during the design/detail engineering phase, supplier shall submit the following details and information on gearboxes.

D2.1. Design Calculations and Manufacturing Procedure:

a) Power rating of gearbox. b) Service factor/application factor considered. c) Gear reduction ratio. d) Maximum input speed/output speed considered in design e) Max torque considered for design. f) Design calculations for gears/shafts/bearing selection g) Material of gears/pinion & hardness values with test certificates. h) Fits and tolerances provided on the interfaces of gears/shaft, bearing/shaft,

bearing/housing, and other locating surfaces. i) Surface roughness values. j) Balancing of rotating elements k) Manufacturing & heat treatment procedure. l) Gearbox lubrication scheme.

D2.2 Reference of relevant standards followed for design, manufacture and acceptance norms.

D2.3 Inspection/Testing Norms:

a. Before assembly of gearbox all the drive components / gears/bearings will be inspected by purchaser’s representative/ third party inspector at supplier premises.

b. After assembly of Gearbox running test shall conducted and the following tests shall be conducted.

i) Checking the run out of input/output shafts. ii) Noise test: Noise level shall be not more than 85db from 1m distance. iii) Vibration test: Double amplitude of vibration (of each shaft in any plane

shall not exceed 50 micrometer value. iv) Thermal capacity test (i.e., after running the gearbox for 4 hrs.

Temperature rise in the gearbox shall not exceed 38°C over the ambient temperature)

The gearbox assembly shall meet all above test requirements. i) The necessary testing instruments shall be provided by crane supplier while conducting

above test at manufacturers’ site. ii) The noise level test shall be repeated after erection of crane at our site.

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ANNEXURE-6 E. CODES AND STANDARDS Design, manufacture and testing of the crane shall conform to the latest editions of the following codes and standards:

S.No. IS CODE DESCRIPTION CRANE RELATED

1. IS:2062 Hot rolled medium and High Tensile Structural Steel-Specification 2. IS:800 General construction in Steel-Code of Practice 3. IS:807 Design, Erection and Testing (Structural Portion) of Cranes and Hoists-

Code of Practice 4. IS:3177 Code of Practice for Electric Overhead Traveling Cranes and Gantry

Cranes other than Steel Works Cranes 5. IS:4137 Code of Practice for Heavy Duty Electric Overhead Traveling Cranes

including special service machines for use in Steel Works 6. IS:3815

IS:15560 Point Hook with Shanks for General Engineering purpose

7. IS:3443 Specification for Crane Rail Sections 8. IS:3138 Specification for hexagonal bolts and nuts 9. IS:2048 Specification for parallel keys and keyways 10. ANSI

B30.2.0 Safety Codes for overhead and Gantry Cranes

11. IS:816 Code of Practice for Use of Metal Arc Welding for general Construction in Mild Steel

12. IS:1181 Qualifying Tests for Metal Arc Welders (Engaged in Welding Structures other than pipes)

13. IS:1323 Code of Practice for Oxy-Acetylene Welding for Structural Work in Mild steel

14. ANSI/AWS D14.1

Structural Welding code : Code of welding practice for Mill cranes and other material handling equipment

15. IS 1024 1999 Use of Welding in Bridges and Structures Subject to Dynamic Loading - Code of Practice

16. IS 7403 1974 Code of Practice for Selection of Standard Worm and Helical Gear Boxes

17. IS 4460 Parts 1 to 3 : 1995 Gears - Spur and Helical Gears - Calculation of Load Capacity

18. IS 8610 1977 Specification for Point Hooks with Shank Capacity Up to 25 Tonnes-Trapezoidal Section

19. IS 3815 1969 Specification for point hooks with shank for general engineering purposes

20. IS 6294 1971 Specification for Point Hooks with Shank (for Capacities 63 Tonnes to 160 Tonnes)

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21. WIRE ROPE RELATED 22. IS:1835 Steel Wires for Ropes 23. IS:2266 Steel Wire Ropes for General Engineering Purposes 24. IS:6594 Technical supply conditions for steel wire ropes and strands 25. IS:3973 Selection, installation, maintenance and technical supply conditions of

wire ropes 26. ELECTRICAL ITEMS RELATED 27. IS:325 Three Phase induction Motors 28. IS:4029 Guide for Testing Three Phase induction Motor 29. IS:2147 Degrees of protection provided by enclosures for low voltage switch

gear and control gear 30. IS:1554 PVC Insulated (Heavy Duty) electric cables 31. IS:2208 HRC cartridge fuse links up to 650V 32. IS:2959 Contactors for voltage not exceeding 1000V AC or 1200V DC 33. IS:4064 Air-break switches, Air-break dis-connector, Air-break switch dis-

connector and fuse combination for voltages not exceeding 1000V AC. or 1200V DC

34. IS:4237 General requirements of switch gears and control gears for voltages not exceeding 1000V AC

35. IS:8623 Factory-built assemblies of switch gears and control gears for voltages not exceeding 1000V AC (or) 1200V DC

36. IS:8544 Motor starters for voltages not exceeding 1000V 37. IS:5571 Guide for selection of electrical equipment for hazardous areas 38. IS:5572 Classification of Hazardous Areas (Other than Mines) for electrical

installations 39. IS 2148 1981 Flame-proof enclosures for electrical apparatus 40. IS 5780 1980 Specification for Intrinsically Safe Electrical Apparatus and

Circuits 41. IS:4237 General requirements of switch gears and control gears for voltages not

exceeding 1000V AC 42. IS 13947 Part 4 : Sec 1 : 1993 /IEC Pub 947-4-1 : 1990 Specification for Low-

Voltage Switchgear and Controlgear - Part 1 to Part 5 : Contractors and Motor-Starters - Section 1 : Electromechanical Contactors and Motor Starters

43. IS:10118 1982 Code of Practice for Selection, Installation and Maintenance of Switchgear and Control gear

Part I : General Part II : Selection Part III : Installation Part IV : Maintenance

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ANNEXURE – 7

CALCULATIONS TO BE SUBMITTED

Supplier shall submit the following calculations (as part of design report) along with G.A drawing after receipt of P.O.

1. SIZING CALCULATIONS

1. Motor Selection – i) Hoist ii) Travel Motion for CT & LT

2. Brake Selection – i) Hoist ii) LT (Main & Micro) iii) CT (Main & Micro)

3. Wire rope 4. Sheaves 5. Rope drum – i) Thickness

ii) Dia iii) Length

6. Gear box selection – (M.H, CT, LT )

7. Gear box calculations – As per Annexure-5 D2.1

8. Coupling selection – i) Input, ii) Output iii) Hoist

9. Bearing life – i) CT ii) LT

10. Angular twist for shaft – i) CT ii) LT iii) Rigid shaft

11. Wheel selection – i) Load ii) Diameter selection for CT & LT

12. Rail selection – CT & LT 13. Braking path calculations for – i) Main Hoist

ii) CT iii) LT

14. Calculation of fleet angle for pulleys

15. Contact stress between wheel and Rail

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2. STRUCTURAL & DESIGN CALCULATIONS:

1) Main Girder calculations 2) Camber calculations 3) Welding design of Main girder and end carriage 4) Collision effects 5) End carriage calculations 6) Diaphram calculations – I) Main Girder

II) End Carriage 7) Joints between main girder and end carriage 8) Crab calculations 9) Deflection calculations

3. Drawings:

1) G.A drawings 2) Main Girder drawings 3) End carriage drawings 4) Crab drawings 5) Hook approaches drawings 6) LT arrangement 7) Snatch Block assembly. 8) Gear box layout

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ANNEXURE – 8

TEST CERTIFICATES & INSPECTION REPORTS TO BE SUBMIT TED

Supplier shall submit the following reports along with G.A drawing after receipt of P.O.

1. Raw Material Test Reports (Chemical composition & Mechanical Properties) 2. Welding Procedure qualification/Procedure qualification Records(PQR) 3. Girder and End carriage Inspection Reports 4. DP Test Reports of fillet weld joints of girders 5. Rope Drum SR Charts 6. Rope Drum fillet joint DP Test report 7. Gear Box Reports 8. Dimensional Reports including tolerances of Key & Key ways of Gear Box 9. MH, LT, CT & Wheels 10. Key material Test certificates 11. CT/LT Wheel Physical /Chemical Properties Reports 12. Wheel Hardness Test Reports 13. Wheel UT Report 14. Wheel Dimensional Report 15. Hook Test Report 16. Coupling Test Certificates 17. Dimensional Reports of Couplings 18. Brake Drum Dynamic Balancing Reports 19. Material & Dimensional Report for Sheaves 20. Inspection Report for lower block assembly 21. Wire rope Test Certificates 22. Flame Proof Certificates of EHT Brakes, Thruster, Motors & Panels 23. Control Panel Inspection Reports 24. Motor Test Certificate 25. Brake Test Certificate 26. Inspection Reports As Per ISRO Crane Test Procedure 27. Painting Inspection Report 28. Load test report

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ANNEXURE-9 FORMAT FOR PRICE BID (PART-II)

Party shall quote the prices in the format as given below. If particular charge is not applicable it can be mentioned as “Nil ”. If particular charge is combined in the basic price it shall be mentioned as “Included in basic price”

EOT Crane: Flame proof, Double girder, 30 ton Capacity, 19m span, 14m lift, Building Length: 60m

Erection of LT gantry girder is in the scope of Purchaser

Sl.No. DESCRIPTION Cost (Rs.)

1. Base Price for Design, fabrication and supply of EOT CRANE (excluding LT Rails and Power Supply system)

2.

Erection & Commissioning charges for EOT crane at purchaser’s site (SDSC SHAR) inclusive of following.

• Tools, tackles and machinery required for erection & commissioning

• Sufficient quantity of Gear box oil, lubricants required for first filling

3. Price for Supply of LT gantry Rails of size _____ (lb/yd) with mounting clamps & accessories for 60m long building

4. Erection charges for LT gantry rails on Gantry Girder

5. Supply of power supply arrangement for 60m bay length (Electric cables & chain drag system for CT, LT)

6. Erection charges for power supply arrangement (Electric cables & chain drag system for CT, LT)

7. Charges for Third party inspection (EOT crane design, manufacture, erection & commissioning

8. Transportation charges for crane and all related parts (Inclusive of unloading & handling of items at site)

9. Packing & Forwarding charges 10. Tool box (Detailed List of tools should be Enclosed)

11. Essential Spares for two years normal maintenance (List & Individual price shall be mentioned as per C21)

12. Sales Tax / VAT 13. Excise duty 14. Service tax on erection charges (%) 15. Additional charges (If any)

TOTAL COST

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